Wacker Neuson RTKx-SC3 User manual

Operator’s Manual

Trench Roller

RT82-SC3

RTx-SC3

Type RT82-SC3, RTx-SC3

Document 5200023365

Date

1016

Version 06

Language EN

5200023365

Copyright notice

All rights, including copying and distribution rights, are reserved.

This publication may be photocopied by the original purchaser of the

machine. Any other type of reproduction is prohibited without express

written permission from Wacker Neuson Production Americas LLC.

Any type of reproduction or distribution not authorized by Wacker

Neuson Production Americas LLC represents an infringement of valid

copyrights. Violators will be prosecuted.

Trademarks

All trademarks referenced in this manual are the property of their

respective owners.

Manufacturer

Wacker Neuson Production Americas LLC

N92W15000 Anthony Avenue

Menomonee Falls, WI 53051 U.S.A.

Tel: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957

www.wackerneuson.com

Original instructions

This Operator’s Manual presents the original instructions. The original

language of this Operator’s Manual is American English.

RT / RTx Foreword

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Foreword

SAVE THESE INSTRUCTIONS—This manual contains important instructions for

the machine models below. These instructions have been written expressly by

Wacker Neuson Production Americas LLC and must be followed during installation,

operation, and maintenance of the machines.

Machine

identification

A nameplate listing the model number, item number, revision number, and serial

number is attached to this machine. The location of the nameplate is shown above.

Serial number

(S/N)

For future reference, record the serial number in the space provided below. You will

need the serial number when requesting parts or service for this machine.

Machine Item Number

RT82-SC3 5200019232, 5200019233,

5200019234, 5200019235,

5200019236, 5200019237,

5200019238, 5200019239,

5200022541, 5200019255,

5200019256

RTx-SC3 5200019250, 5200019251,

5200019252, 5200019253,

5200019254, 5200019257,

5200019258, 5200019259,

5100018515, 5100018516,

5100018517, 5100018518

wc_gr012199

Serial Number:

Foreword RT / RTx

4 wc_tx003861gb_FM10.fm

Machine

documentation

■ From this point forward in this documentation, Wacker Neuson Production

Americas LLC will be referred to as Wacker Neuson.

■ Keep a copy of the Operator’s Manual with the machine at all times.

■ For spare parts information, please see your Wacker Neuson Dealer, or visit the

Wacker Neuson website at http://www.wackerneuson.com/.

■ When ordering parts or requesting service information, be prepared to provide

the machine model number, item number, revision number, and serial number.

Expectations

for

information in

this manual

■ This manual provides information and procedures to safely operate and

maintain the above Wacker Neuson model(s). For your own safety and to

reduce the risk of injury, carefully read, understand, and observe all instructions

described in this manual.

■ Wacker Neuson expressly reserves the right to make technical modifications,

even without notice, which improve the performance or safety standards of its

machines.

■ The information contained in this manual is based on machines manufactured

up until the time of publication. Wacker Neuson reserves the right to change any

portion of this information without notice.

■ The illustrations, parts, and procedures in this manual refer to Wacker Neuson

factory-installed components. Your machine may vary depending on the

requirements of your specific region.

CALIFORNIA

Proposition

65 Warning

Combustion exhaust, some of its constituents, and certain vehicle components

contain or emit chemicals known to the State of California to cause cancer and

birth defects or other reproductive harm.

Laws

pertaining to

spark

arresters

NOTICE: State Health Safety Codes and Public Resources Codes specify that in

certain locations spark arresters be used on internal combustion engines that use

hydrocarbon fuels. A spark arrester is a device designed to prevent accidental

discharge of sparks or flames from the engine exhaust. Spark arresters are

qualified and rated by the United States Forest Service for this purpose. In order to

comply with local laws regarding spark arresters, consult the engine distributor or

the local Health and Safety Administrator.

RT / RTx Foreword

wc_tx003861gb_FM10.fm 5

Manufacturer’s

approval

This manual contains references to approved parts, attachments, and

modifications. The following definitions apply:

■ Approved parts or attachments are those either manufactured or provided by

Wacker Neuson.

■ Approved modifications are those performed by an authorized Wacker

Neuson service center according to written instructions published by Wacker

Neuson.

■ Unapproved parts, attachments, and modifications are those that do not

meet the approved criteria.

Unapproved parts, attachments, or modifications may have the following

consequences:

■ Serious injury hazards to the operator and persons in the work area

■ Permanent damage to the machine which will not be covered under warranty

Contact your Wacker Neuson dealer immediately if you have questions about

approved or unapproved parts, attachments, or modifications.

Foreword RT / RTx

6 wc_tx003861gb_FM10.fm

2016-CE-RTx_Kohler_en_FM10.fm

EC Declaration of Conformity

Manufacturer

Wacker Neuson Production Americas LLC, N92W15000 Anthony Avenue,

Menomonee Falls, Wisconsin 53051 USA

Product

Product category

Product function

Item number

Net installed power

Measured sound power level

Guaranteed sound power level

RT82-SC3, RTx-SC3

Trench Roller

To compa c t s o i l

5200019235, 5200019236, 5200019237, 5200019238,

5200019239, 5200019252, 5200019253, 5200019254,

5200022541, 5100018516

15.5 kW

106 dB(A)

109 dB(A)

Conformity Assessment Procedure

According to 2000/14/EC ANNEX VIII

Notified Body

Lloyds Register Verification Limited (Notified Body No 0038)

71 Fenchurch Street, London EC3M 4BS, United Kingdom

Directives and Standards

We hereby declare that this product meets and complies with the relevant regulations and

requirements of the following directives and standards:

2006/42/EC, 2000/14/EC, 2005/88/EC, 2014/30/EU, EN 500-1, EN 500-4

Authorized Person for Technical Documents

Robert Raethsel, Wacker Neuson Produktion GmbH & Co. KG, Wackerstrasse 6, 85084

Reichertshofen, Germany

Menomonee Falls, WI, USA, 27.05.16

Original Declaration of Conformity

Paul Sina

Manager, Product Engineering

For Wacker Neuson

Jeff Volden

Director, Product Engineering

For Wacker Neuson

Keith Herr

Vice President and Managing Director

For Wacker Neuson

2016-CE-RTx_Kubota_en_FM10.fm

EC Declaration of Conformity

Manufacturer

Wacker Neuson Production Americas LLC, N92W15000 Anthony Avenue,

Menomonee Falls, Wisconsin 53051 USA

Product

Product category

Product function

Item number

Net installed power

Measured sound power level

Guaranteed sound power level

RT82-SC3, RTx-SC3

Trench Roller

To comp a c t soil

5200019256, 5200019259, 5100018518

15.5 kW

105 dB(A)

109 dB(A)

Conformity Assessment Procedure

According to 2000/14/EC ANNEX VIII

Notified Body

Lloyds Register Verification Limited (Notified Body No 0038)

71 Fenchurch Street, London EC3M 4BS, United Kingdom

Directives and Standards

We hereby declare that this product meets and complies with the relevant regulations and

requirements of the following directives and standards:

2006/42/EC, 2000/14/EC, 2005/88/EC, 2014/30/EU, EN 500-1, EN 500-4

Authorized Person for Technical Documents

Robert Raethsel, Wacker Neuson Produktion GmbH & Co. KG, Wackerstrasse 6, 85084

Reichertshofen, Germany

Menomonee Falls, WI, USA, 27.05.16

Original Declaration of Conformity

Paul Sina

Manager, Product Engineering

For Wacker Neuson

Jeff Volden

Director, Product Engineering

For Wacker Neuson

Keith Herr

Vice President and Managing Director

For Wacker Neuson

Table of Contents

RT / RTx

wc_bo5200023365_06_FM10TOC.fm

11

Foreword 3

EC Declaration of Conformity 7

1 Safety Information 15

1.1 Signal Words Used in this Manual ..................................................... 15

1.2 Machine Description and Intended Use ............................................. 16

1.3 Safety Guidelines for Operating the Machine ..................................... 17

1.4 Service Safety .................................................................................... 19

1.5 Operator Safety while Using Internal Combustion Engines ............... 21

1.6 Hydraulic Fluid Safety ........................................................................ 22

1.7 Safety Guidelines for Lifting the Machine ........................................... 22

2 Labels 24

2.1 Label Locations .................................................................................. 24

2.2 Label Meanings .................................................................................. 26

3 Lifting and Transporting 35

3.1 Articulated Joint Locking Bar .............................................................. 35

3.2 Lifting the Machine ............................................................................. 36

3.3 Tying Down and Transporting the Machine ........................................ 37

4 Operation 39

4.1 Preparing the Machine for First Use ................................................... 39

4.2 Control and Component Locations—Kohler ....................................... 40

4.3 Control / Component Descriptions—Kohler ....................................... 41

4.4 Control and Component Locations—Kubota ...................................... 42

4.5 Control / Component Descriptions—Kubota ...................................... 43

4.6 Features and Controls ........................................................................ 44

4.7 Accessing the Engine or Hydraulic Component Compartments ......... 45

4.8 Accessing the Control Compartment .................................................. 45

4.9 Control Panel ...................................................................................... 46

4.10 SmartControl™ SC-3 Transmitter ...................................................... 48

4.11 Operating Status Indicator Codes ...................................................... 50

4.12 Light Ring Color Codes ...................................................................... 52

4.13 Infra-red System and Control Channels ............................................. 53

4.14 Function of the Compatec Compaction System (if equipped) ............ 55

Table of Contents

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12

4.15 Position of the Operator ......................................................................57

4.16 Range Limits .......................................................................................58

4.17 Operating Characteristics ...................................................................59

4.18 Communication Faults ........................................................................59

4.19 Machine Stability .................................................................................60

4.20 Operating on Slopes ...........................................................................61

4.21 Rollovers .............................................................................................61

4.22 Refueling the Machine ........................................................................62

4.23 Before Starting ....................................................................................63

4.24 Starting, Operating, and Stopping the Machine ..................................64

4.25 Emergency Shutdown Procedure .......................................................67

4.26 NiMH Battery ......................................................................................68

4.27 Replacing the Battery Pack ................................................................68

4.28 Charging the Transmitter Battery ........................................................69

5 Engine Control Module (ECM) Diagnostics 71

5.1 Overview of the ECM and the Diagnostic Tool ...................................71

5.2 ECM Stages of Engine Start Up .........................................................72

5.3 ECM Monitoring of Solenoids—Kohler Engine Only ...........................73

5.4 ECM Monitoring of Solenoids—Kubota Engine Only ..........................74

5.5 Connecting the Diagnostic Tool—Kohler Engine Only .......................76

5.6 Connecting the Diagnostic Tool—Kubota Engine Only ......................77

5.7 Programming the ECM Tip-Over Mode ..............................................78

5.8 Entering the ECM Diagnostic Mode ....................................................79

5.9 ECM Fault and Error Codes ...............................................................80

5.10 Resetting the ECM Diagnostic Data and the Tip-Over Light ..............82

5.11 Calibrating the Joysticks .....................................................................83

6 Changing Drums (RTx-SC3) 85

6.1 Removing the Drum Extensions .........................................................85

6.2 Installing Drum Extensions .................................................................87

7 General Maintenance 90

7.1 Periodic Maintenance Schedule .........................................................90

7.2 Hydraulic Oil Requirements ................................................................91

7.3 Checking the Hydraulic Oil Level ........................................................92

7.4 Changing Hydraulic Oil and Filter .......................................................93

7.5 Lubricating the Articulated Joint and Steering Cylinders ....................95

Table of Contents

RT / RTx

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13

7.6 Cleaning SmartControl™ Transmitter ................................................ 96

7.7 Scraper Bars ...................................................................................... 97

7.8 Shock Mounts ..................................................................................... 97

7.9 Maintaining the Battery ....................................................................... 98

7.10 Draining the Fuel Filter Water Separator—Kohler Engine Only ......... 99

7.11 Maintaining the Fuel Filter Water Separator—Kubota Engine Only . 100

7.12 Priming the Fuel System—Kohler Engine Only ................................ 101

7.13 Storage ............................................................................................. 102

7.14 Long-Term Storage .......................................................................... 103

7.15 Machine Disposal / Decommissioning .............................................. 104

8 Engine Maintenance: Kohler (T4f) 105

9 Engine Maintenance: Kubota D902 110

10 Troubleshooting 113

10.1 Checking Hydraulic Pressure ........................................................... 115

10.2 Hydraulic Manifold ............................................................................ 116

11 Technical Data 117

11.1 Engine .............................................................................................. 117

11.2 Roller ................................................................................................ 118

11.3 Lubrication ........................................................................................ 118

11.4 Sound and Vibration Specifications .................................................. 119

11.5 Dimensions ....................................................................................... 119

11.6 Radiation Compliance ...................................................................... 119

12 Emission Control Systems Information and Warranty—Diesel 121

12.1 Emission Control System Background Information .......................... 121

12.2 Limited Defect Warranty for Wacker Neuson Emission Control

Systems ............................................................................................ 122

13 AEM Safety Manual 127

Table of Contents

RT / RTx

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14

14 Schematics 149

14.1 Electrical Schematic—Complete—Kohler .........................................150

14.2 Electrical Schematic Components—Kohler .......................................151

14.3 Electrical Schematic Section A—Kohler ............................................152

14.4 Electrical Schematic Components—Kohler .......................................153

14.5 Electrical Schematic Section B—Kohler ............................................154

14.6 Electrical Schematic Components—Kohler .......................................155

14.7 Electrical Schematic Section C—Kohler ...........................................156

14.8 Electrical Schematic Components—Kohler .......................................157

14.9 Electrical Schematic Section D—Kohler ...........................................158

14.10 Electrical Schematic Components—Kohler .......................................159

14.11 Electrical Schematic—Complete—Kubota ........................................160

14.12 Electrical Schematic Components—Kubota ......................................161

14.13 Electrical Schematic Section A—Kubota ...........................................162

14.14 Electrical Schematic Components—Kubota ......................................163

14.15 Electrical Schematic Section B—Kubota ...........................................164

14.16 Electrical Schematic Components—Kubota ......................................165

14.17 Electrical Schematic Section C—Kubota ..........................................166

14.18 Electrical Schematic Components—Kubota ......................................167

14.19 Electrical Schematic Section D—Kubota ..........................................168

14.20 Electrical Schematic Components—Kubota ......................................169

14.21 Electrical Schematic — Compatec Compaction Display

(if equipped) ......................................................................................170

14.22 Electrical Schematic Components — Compatec Compaction

Display (if equipped) ..........................................................................171

14.23 Hydraulic Schematic — 1 ..................................................................172

14.24 Hydraulic Schematic Components — 1 .............................................173

14.25 Hydraulic Schematic — 2 ..................................................................174

14.26 Hydraulic Schematic Components — 2 .............................................175

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15

RT / RTx Safety Information

1 Safety Information

1.1 Signal Words Used in this Manual

This manual contains DANGER, WARNING, CAUTION, NOTICE, and NOTE

signal words which must be followed to reduce the possibility of personal injury,

damage to the equipment, or improper service.

NOTICE: Used without the safety alert symbol, NOTICE indicates a situation

which, if not avoided, could result in property damage.

Note: A Note contains additional information important to a procedure.

This is the safety alert symbol. It is used to alert you to potential personal hazards.

► Obey all safety messages that follow this symbol.

DANGER

DANGER indicates a hazardous situation which, if not avoided, will result in death

or serious injury.

► To avoid death or serious injury from this type of hazard, obey all safety

messages that follow this signal word.

WARNING

WARNING indicates a hazardous situation which, if not avoided, could result in

death or serious injury.

► To avoid possible death or serious injury from this type of hazard, obey all safety

messages that follow this signal word.

CAUTION

CAUTION indicates a hazardous situation which, if not avoided, could result in

minor or moderate injury.

► To avoid possible minor or moderate injury from this type of hazard, obey all

safety messages that follow this signal word.

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Safety Information RT / RTx

1.2 Machine Description and Intended Use

This machine is a remote-controlled trench roller. The Wacker Neuson Trench

Roller consists of two distinct machine halves (front and rear) joined by an

articulated joint. Each machine half includes an exciter assembly and two drums.

The front half also includes a diesel engine and pumps for the hydraulic system.

The rear half includes the hydraulic oil reservoir and the fuel tank. The diesel

engine powers the hydraulic systems that provide machine movement and drum

vibration. The operator controls all machine functions (steering, vibration, and

engine start/stop) using an infra-red control system.

This machine is intended to be used for compacting sub-bases, backfill, and

cohesive type soils.

This machine has been designed and built strictly for the intended use(s) described

above. Using the machine for any other purpose could permanently damage the

machine or seriously injure the operator or other persons in the area. Machine

damage caused by misuse is not covered under warranty.

The following are some examples of misuse:

■ Using the machine as a ladder, support, or work surface

■ Using the machine to carry or transport passengers or equipment

■ Using the machine to tow other machines

■ Operating the machine outside of factory specifications

■ Operating the machine in a manner inconsistent with all warnings found on the

machine and in the Operator’s Manual

This machine has been designed and built in accordance with the latest global

safety standards. It has been carefully engineered to eliminate hazards as far as

practicable and to increase operator safety through protective guards and labeling.

However, some risks may remain even after protective measures have been taken.

They are called residual risks. On this machine, they may include exposure to:

■ Heat, noise, exhaust, and carbon monoxide from the engine

■ Burns from hot hydr

aulic fluid

■ Fire ha

zards from improper refueling technique

s

■ Fuel and its fumes

■ Personal injury from improper lifting techniques

■ Crushing hazards from improper operation and for other persons in th

e work

zone

T

o protect yourself and others, make sure you thoroughly read and understand the

safety information presented in this manual before operating the machine.

wc_si000902gb_FM10.fm

17

RT / RTx Safety Information

1.3 Safety Guidelines for Operating the Machine

Operator

training

Before operating the machine:

■ Read and understand the operating instructions contained in all manuals

delivered with the machine.

■ Familiarize yourself with the location and proper use of all controls and safety

devices.

■ Contact Wacker Neuson for additional training if necessary.

When operating this machine:

■ Do not allow improperly trained people to operate the machine. People

operating the machine must be familiar with the potential risks and hazards

associated with it.

Operator

qualifications

Only trained personnel are permitted to start, operate, and shut down the machine.

They also must meet the following qualifications:

■ have received instruction on how to properly use the machine

■ are familiar with required safety devices

The machine must not be accessed or operated by:

■ children

■ people impaired by alcohol or drugs

Application

area

Be aware of the application area.

■ Keep unauthorized personnel, children, and pets away from the machine.

■ Remain aware of changing positions and the movement of other equipment and

personnel in the application area/job site.

■ Identify whether special hazards exist in the application area, such as toxic

gases or unstable ground conditions, and take appropriate action to eliminate

the special hazards before using the machine.

Be aware of the application area.

■ Do not operate the machine in areas that contain flammable objects, fuels, or

products that produce flammable vapors.

■ Always use the SmartControl™ transmitter neck strap provided by Wacker

Neuson while operating with the control cable connected. This neck strap is

designed to break away so that the operator will not be dragged by the machine

should the machine slide, tip, or fall.

■ Always remain in visual contact with the machine at all times while operating the

controls.

■ Never operate multiple rollers within 20 meters (65 feet) of one another, unless

you are certain that each roller and its accompanying transmitter have been set

to a different control channel than the other rollers/transmitters being used

within the area. Refer to section Setting Control Channels for additional

information.

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18

Safety Information RT / RTx

Safety

devices,

controls, and

attachments

Only operate the machine when:

■ All safety devices and guards are in place and in working order.

■ All controls operate correctly.

■ The machine is set up correctly according to the instructions in the Operator’s

Manual.

■ The machine is clean.

■ The machine’s labels are legible.

To ensure safe operation of the machine:

■ Do not operate the machine if any safety devices or guards are missing or

inoperative.

■ Do not modify or defeat the safety devices.

■ Only use accessories or attachments that are approved by Wacker Neuson.

■ Use caution when operating near the edges of pits, trenches or platforms.

Check to be sure that the ground surface is stable enough to support the weight

of the machine with the operator and that there is no danger of the roller sliding,

falling, or tipping.

■ Position yourself safely when operating machine in reverse or on hills. Leave

enough space between yourself and the machine so you will not be placed in a

hazardous position should the machine slide or tip.

■ Do not use a cellphone or send text messages while operating this machine.

■ Stay clear of the articulated steering joint and the area between the front and

rear frames.

■ Do not consume the operating fluids used in this machine. Depending on your

machine model, these operating fluids may include water, wetting agents, fuel

(gasoline, diesel, kerosene, propane, or natural gas), oil, coolant, hydraulic fluid,

heat transfer fluid (propylene glycol with additives), battery acid, or grease.

Personal

Protective

Equipment

(PPE)

Wear the following Personal Protective Equipment (PPE) while operating this

machine:

■ Close-fitting work clothes that do not hinder movement

■ Safety glasses with side shields

■ Hearing protection

■ Safety-toed footwear

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19

RT / RTx Safety Information

1.4 Service Safety

Service

training

Before servicing or maintaining the machine:

■ Read and understand the instructions contained in all manuals delivered with

the machine.

■ Familiarize yourself with the location and proper use of all controls and safety

devices.

■ Only trained personnel shall troubleshoot or repair problems occurring with the

machine.

■ Contact Wacker Neuson for additional training if necessary.

When servicing or maintaining this machine:

■ Do not allow improperly trained people to service or maintain the machine.

Personnel servicing or maintaining the machine must be familiar with the

associated potential risks and hazards.

Precautions

When servicing or maintaining the machine:

■ Read and understand the service procedures before performing any service to

the machine.

■ All adjustments and repairs must be completed before operating the machine.

Do not operate the machine with a known problem or deficiency.

■ All repairs and adjustments shall be completed by a qualified technician.

■ Turn off the machine before performing maintenance or making repairs.

■ Remain aware of the machine’s moving parts. Keep hands, feet, and loose

clothing away from the machine’s moving parts.

■ Re-install the safety devices and guards after repair and maintenance

procedures are complete.

■ Always secure the articulated steering joint using the locking bar before lifting,

jacking, and servicing the machine. The machine halves could swing together

unexpectedly and cause a serious injury.

■ Do not remove the radiator cap when the engine is running or hot. The radiator

fluid is hot and under pressure and may cause severe burns!

■ Do not remove air cleaner cover, paper element, or precleaner while engine is

running.

■ Do not leave SmartControl™ transmitter unattended while servicing machine.

Machine

modifications

When servicing or maintaining the machine:

■ Use only accessories/attachments that are approved by Wacker Neuson.

When servicing or maintaining the machine:

■ Do not defeat safety devices.

■ Do not modify the machine without the express written approval of Wacker

Neuson.

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20

Safety Information RT / RTx

Replacing

parts and

labels

■ Replace worn or damaged components.

■ Replace all missing and hard-to-read labels.

■ When replacing electrical components, use components that are identical in

rating and performance to the original components.

■ When replacement parts are required for this machine, use only Wacker

Neuson replacement parts or those parts equivalent to the original in all types of

specifications, such as physical dimensions, type, strength, and material.

Cleaning

When cleaning and servicing the machine:

■ Keep the machine clean and free of debris such as leaves, paper, cartons, etc.

■ Keep the labels legible.

When cleaning the machine:

■ Do not clean the machine while it is running.

■ Never use gasoline or other types of fuels or flammable solvents to clean the

machine. Fumes from fuels and solvents can become explosive.

Personal

Protective

Equipment

(PPE)

Wear the following Personal Protective Equipment (PPE) while servicing or

maintaining this machine:

■ Close-fitting work clothes that do not hinder movement

■ Safety glasses with side shields

■ Hearing protection

■ Safety-toed footwear

In addition, before servicing or maintaining the machine:

■ Tie back long hair.

■ Remove all jewelry (including rings).

After Use

■ Stop the engine when the machine is not being operated.

■ Close the fuel valve on engines equipped with one when machine is not being

operated.

■ Ensure that the machine will not tip over, roll, slide, or fall when not being

operated.

■ Store the machine properly when it is not being used. The machine should be

stored in a clean, dry location out of the reach of children.

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